Roofing



' HY. l c. AVERY ROOFING Nw; 16, S1937.

Original Filed March 28, 1932 192 Je for f/ezr atented Nov. i6, g' l Boomer Henry C. Avery, New Brunswick, N. J., assignor to The Patent and Licensing Corporation, New York, N. Y., a corporation of Massachusetts Original application March 28, 1932, Serial No. 601,702. Divided and this application May 9, 1934, Serial No. 724,721

1 claim. (ci. 91-68) 'Ihis invention relates to composition roofing layer is in time affected by the action of atmosand has moreparticular reference to an improvedv pheric conditions normally existing in actual use l asphaltic roofing material and a method of proto such an extent that ultimately it ceases to ducing the same. My invention finds one parprovide the necessary protection to the roofing 5 ticular adaptation in that type of roofing which base. While the material which is usually em- 5 consists of a felted foundation of fibrous maployed as the coating for the roofing base is terial, such as rag or asbestos or similar fibers generally a blown asphalt having a melting point formed into a sheet cn a paper making machine, of about 220 F., I have found that nevertheless and converted into material suitable for use as the atmospheric conditions to which the roofing roong by saturating the felted sheet with a material is sometimes subjected, are suiicient to lo waterproof saturant such as molten asphalt, and induce what appears to be a very slow and irreguthen coating on one or both faces thereof, with lar internal flow of the coating material, the waterproof and Weatherproof material such as nature and extent of which Varies with the varybloWn asphalt. This coating material is usually ing weathering conditions to which the material spread upon the sheetin a layer of suicient may be subjected. Apparently under the in- 15 thickness to provide a barrier to the entrance of uence of the solar rays and sometimes also moisture into the pore spaces of the sheet, and to under the action of the excessive temperatures otherwise protect the sheet against the influence of the roof-supporting structure, there is caused of the elements. As already indicated, one of more or less internal flow of the coating material the important functions of the layer of coating in various directions and in irregular degree, due 20 material, is to prevent the absorption of moisture apparently to the polymerization and surface by the sheet, since the absorption of moisture hardening and shrinkage of the exposed coating renders the material liable to deterioration upon layer induced by the normal weathering effects. exposure to the changing weather conditions, by The slipping of the polymerized and hardened virtue of the fact that the absorbed moisture surface layer over the softer and yet unaffected 25 tends to swell or bulk the felted base and cause portion of the coating layer, causes the formervto disintegration thereof under the changing crack and the softer portions to ow into the weather conditions. It is important that the cracks thus produced. It Will be appreciated, of layer of coating material lshould preserve its course, that this flow and the displacement of flexibility and ductility as long as possible and the harder material by the softer, is indeed im- 30 retain its integrity so as to properly protect the perceptibly slow and can be observed only upon sheet against the entrance of moisture thereinto, examination of the coating layer over considerand otherwise enable the coating layer to perform able periods of time. It is a fact, nevertheless, its protective functions. that this ow does occur and proceeds continu- The coatingflayer applied to the face of the ally, with the formation, as a result thereof, of 35 sheet which will normally constitute `the exposed numerous ridges or crests and furrows or valleys surface of the roofing material may have imdistributedy in irregular fashion over the surface bedded therein a layer of grit or crushed mineral of the roofing base, and ordinarily giving a crazed or any suitable form such as crushed slate or the or checked appearance thereto. These formalike, the purpose of which is to provide a masking tions, Whichl believe to be due to the aforesaid 40 layer of Wear and'weather resistant material for occurrence of internal iioW, may be readily noted the Waterproof coating, and to impart to the upon examination of roong material of this rooting material any desired ornamental color character which has been exposed on a roof for effects. From a sheet thus prepared, there may a considerable length of time, during which it be then cut the Vroofing shingles or shingle has had an opportunity of being subjected to one 45 strips in the form in which they are to be applied or more normal cycles of changing Weather conon the roof or the sheet may be formed into ditions. Manifestly theseV formations detract rolls and applied as roll roofing. from the protective properties of the coating I have heretofore referred to the necessity for layer, since the continuance of this action ulticovering the felted base of this type of roofing mately results in hardening ofthe coating to such 50 with a layerY of coating material of suilcient an extent that the'material becomes brittle, and thickness so as -to afford at al1 times adequate the cracks formed as above described, or by the protection for the felted base. I have observed movement of the roofing base under the action that in the prepared roofing as produced under of wind and local expansion and contraction,

present day commercial operation, the coating give @.CCSSS of moisture to the roofing base and 55 otherwise expose the base to rapid deterioration. 'Ihese diiculties cannot usually be avoided by employing a layer ofI greater thickness or' of a thickness in excess of the usual optimum thicknesswhich ranges from .025 to .060 of an inch, since a layer of asphalt which is too thick is liable to crack from stresses set up'by unequal heat and cooling, especially in winter -Weather when the coating asphalt becomes unusually hard and brittle.

By my present invention I provide a method whereby the foregoing difficulties may be eliminated. In accordance therewith, I combine with the ordinary layer of coating material applied to the sheet in the. manufacture thereof, an additional layer of material which is itself highly water resistant and also capable of resisting to the utmost any tendency for internal flow to take place therein and which furthermore prevents'the internal flow, from taking place in the layer of asphalt thereunder. In this waythe combined layer permanently retains the desirableuniform thickness and avoids the production of checking and crazing on the exposed surface thereof, such as occurs in the rooiing products of this type as now produced.

In carrying out my invention I employ in convjunction with the ordinary layer of coating asphalt a relatively thin overlying layer or lm of a dispersion of waterproofing material. In order to electuate the purposes of my present invention, the dispersion layer must be of a non-drying base such as asphalt,- and the dispersed base should preferably be softer than the underlying coating layer. The dispersion is one which. upon the removal of the water and the coalescence of the dispersed particles assumes a structure rendering it capable of resisting flow at temperatures greatly in excess of the fusing or melting point of the'-dispersed asphalt. Dispersions of asphalt having the aforesaid property of drying to a relatively infusible lm, may be produced in various ways, although I prefer to employ for this purpose a dispersionof asphalt or melting point ranging fromlOO to 'F., made as described in the patentto Lester Kirschbra-un No. 1,620,900.

Asphalt dispersions made in accordance with the Kirschbraun process are capable of drying to a lm of substantial'smoothness, the weathering of the film proceeding uniformlyand without any checking or crazing of the lm. By providing, a film of sufficient thickness, the weathering action is only superficial and does not affect the entire depth of the film. When a dispersion of this character is superposed upon a layer of asphalt and the water is driven off or otherwise removed therefrom, it forms with the subjacent layer of asphalt an inseparable structure. In this structure, the outer layer of coalesced asphalt provides the requisite waterproofing and weatherproof-lng qualities and by virtue of the peculiar physical structure of this composition it is itself completely stable to internal ow and furthermore prevents the occurrence of internal flow in the subjacent layer, or in any case prevents such internal ow from affecting the uniform thickness of the composite layer and evidencing itself in the form of cracks and checks on the outermostsurface thereof. Furthermore,.because of the ilexibility and ductility of the softer asphalt used in producing the dispersion lms of this type and the inability of the films to undergo internal movement, they remain substantially unaffected by extreme conditions of temperature, and no cracking of the outer surface of the composite layer results under such conditions, and the resistance to the destructive action of the weather is thereby greatly prolonged. In order to increase the opacity of the dispersion lm, as well as for other desired e1fects,`suitable fibrous or granular llers may be combined with the dl'spersion.

The principle of my invention as heretofore described may be utilized with advantage in the production of roofing having other than a felted brous base, and protected with an asphaltic layer. Thus, in accordance herewith, the composite layer of asphalt surmounted by a layer of asphalt dispersion may be applied to metallic, and wooden roofing bas/es, as well as to bases composed of various moulded compositions such as cement and the like, or even to bases composed of moulded compositions of asphalt and fiber or other filler.

In the accompanying drawing, the several views are enlarged cross-sections of roong material which may be produced in accordance with my invention.

In these views, numeral I indicates the roofing base Whichmay be a felted sheet, or any other desirable base, such as metal, wood, or a moulded composition.- At 2 is indicated the layer of coating which may be applied in any convenient manner to the base after the formation thereof. The numeral 3 is intended to indicate the layer of coalesced asphalt.

In Fig. 1, the layer of coalesced asphalt 3 provides the finish coat for the roofing and this construction is particularly suitable for the production of a felt base product similar to the rubber roong of commerce, and having no surfacing material in the outermost layer.

In Fig. 2, the layer 3 may have imbedded tween and form a coalesced asphalt layer of desired thickness firmly united to the subjacent layers. If desiredytalc or similar surfacing material may be applied over the layer 3 of coalesced asphalt in the construction illustrated in Fig. 3.

In producing roofing material having a felted brous foundation in accordance with my invention, the usual manner of saturating the felt base sheet -may be followed and after the sheet has been withdrawn from the saturating apparatus and the saturant on the surfaces of the sheet has been absorbed into the pores thereof, the sheet is then conducted to the usual coating rolls where coating asphalt, as for example a 220 F. melting point blown asphalt is applied thereto. The thickness of this coating layer may be substantially the same as is common in the industry, but by suitably adjusting the coating rolls the' thickness of the coating may be varied as desired, so as to produce a thinner Iayerthan the usual coating layer of asphalt. Before this layer of molten asphalt has cooled, there is then applied thereover the dispersed asphalt so as to produce a layer of asphalt dispersion of uniform thickness overlying the relatively hot soft layer of asphalt. In

order that the weathering of the resultant lmv asphalt dispersion may be applied in any con- As the sheet4 progresses in its travel, the heat from the coated base will assist in the evaporation of the water from the layer of asphalt dispersion. Where it is desired to apply mineral surfacing the ysheet may be fed along until the dispersion layer assumes a substantial degree of tackiness, so that the surfacing material may be applied and pressed by suitable rolls into intimate contact with the tacky layer of the asphalt dispersion. As the water becomes completely removed from the dispersion layer, the particles thereof coalesce and at the same time the underlying layer of asphalt cools sufficiently to cause it to harden, the layer of coalesced asphalt thus becoming united into an inseparable structure with the hardened layer of asphalt.

In some cases .the opposite surface of the sheet may also be provided with a coatingllayer of asphalt and in such case, this layer may also have applied thereto an overlying layer of asphalt dis- Y distance, this layer will very quickly'congeal and\ harden. If desired, 'the cooling of the asphalt layer and the solidification thereof may be assisted by direc/ting a blast of cool air uponthe coated sheet, prior to the application of the asphalt dispersion, and similar means may also be employed if desired to assist the removal of water from the dispersion layer to enablethe latter to more quickly dry and harden or reach an adhesive-and tacky condition suitable for the application of the surfacing material thereto, where surfacing material is to be applied.

For certain purposes particularly where the roofing is to be used on a cheaper type of building structure, it is desirable sometimes, for purposes of economy, to omit the granular surfacing material and to finish the roofing with a coating of colored material to impart to the roof at least some degree of ornamentation. In producing rooingV material of this class, in accordance with my invention I employ for the dispersion layer to be applied overthe ordinary asphalt coating, a. dispersion of colorable waterproof pitch, or the like which as before stated is of. a non-drying base, softer than the underlying coating and approximately of the same characteristics as the disper- `sion'iilms applied as previously described. The

dispersion of this material may be formed in accordance with the processes described in the said patent to Lester Kirsch'c-raun', and the dispersed material may then have incorporated therein any desired coloring agent vsuch as mineral pigment,

or the like. The colored dispersion may then be phalt, in accordance with any of the methods above described.

\My invention is also adapted for building up a structure in place upon a roof. For example, asphalt coated roong in the form of rolls may be applied to the roof structure, the successive layers being cemented along the overlapping margins thereof in the well known manner, and thereafter the sheets may be covered with a layer of the dispersion, thelatter being either sprayed or brushed onto the surface and then permitted to dry and harden, and form the composite layer with the coating material of the roofing base as already described. Obviously, mineral or similar surfacing material may, if desired, be distributed in any suitable way in the outermost layer of dispersion, before the latter has completely hardened.

It-will be noted that in all the forms in which my invention may be embodied, I provide a composite coating layer, the outermost portions of which comprise an infusible structure which serves to prevent rapid .deterioration of the fresh and intact subjacent stratum or asphalt or similar coating substance. l

It will be apparent that while I have described my invention in connection with roofing, I do not mean to be restricted thereto, as obviously, many `othervsurfaces which are subjected in use to `film of emulsion, as hereinabovedisclosed, `the grit may beforced through the film of emulsion so that the lower portions ofthe grit part cles:

applied to the sheet previously coated with asbecome partially embedded in the layer of mo ten asphalt before the same has congealed. Thereafter, when the under layer of molten asphalt has vset and the film of emulsion has coalesced, the

grit will be anchored both 'by the asphalt layer and the coalesced emulsion layer, thus offering 'a secure anchorage for the grit.' l y f 'I'his application is a division of my co-'pending application, Serial No. 601,702-, filed`March 28, 1932.

I claim as my invention: y Roofing of the character described comprising a suitable foundation having on the surface ex-` 

